A product and a method of manufacture and assembly of a prefabricated wall panel for construction is shown and described. The present invention is directed towards minimizing the labor of multiple additive steps using many layers and materials seen in many building envelopes.

In one example, the method comprises,

A series of prefabricated residential or commercial building panels made of any of varying materials such as hemperete, fiber, cellulose, plant material, bio-aggregate, aggregate, aerated concrete, composite or inorganic materials, of substantially solid body with channel shaped elongated voids substantially located at the vertical sides as well as horizontally across their top.

Said voids in one panel are a connected channel wrapping around 3 or more sides of the panel and exposed to the exterior of said panel. Said panels are placed side by side around the perimeter of a foundation aligning the channel shaped void in one panel with the respective channel shaped void in the panel beside it creating a concrete form, or form for a load bearing material. Said panels are left in place as an integral part of the wall system. Concrete or other load bearing material is placed in said voids substantially vertically between the panels and across their tops creating an air seal and a mechanical bond between panels. The resulting concrete shape inside the wall is a post and beam structure that is substantially equidistant from the interior and exterior of the wall minimizing heat transfer through thermal bridging and minimizing weathering to the concrete. Many of the requirements of a building's wall such as the insulation, the shear strength, the rough openings for windows and doors, the interior and exterior skin, utility chases, drip edges and trim details can be met by this series of prefabricated building blocks. A method of manufacture of the building panels, the product created by that manufacture, a method of panel assembly and integration with other building components, and the finished product created by the manufacture, assembly and integration with other building components are all shown in the present disclosure.

A building block system of a plurality of transportable, lightweight, and reusable hollow prefabricated non-masonry interlocking mortarless building blocks that have corresponding mating formations being protuberances and concavities that run vertically up the building blocks being joined together and when aligned in a staggered manner upwardly are held together with threaded reinforcement rods extending vertically between and connected to the top and bottom channels through connectable couplings and capped off with complementary cap attachments.

Sinusoidal shaped member units and support member units are parts that form pre-stressed assemblies having flexural properties. Sinusoidal shaped members are relaxed material members that have been elastically deformed. Support members maintain the elastically deformed state of the sinusoidal shaped members. The sinusoidal shaped members and support members are organized into pre-stressed curvilinear assemblies containing stored elastic potential energy that is equal to the work done by the forces that deformed their pre-stressed structure. The assemblies' sinusoidal shaped members and support members are adapted to use materials having exceptional mechanical properties and flexural strength. This includes nano-composites. The assemblies' pre-stressed state enhances its mechanical, electrical and structural performance. The size, number, density and possible geometric configurations of the sinusoidal shaped member units and support member units within an assembly/structure is vast. Products of this sinusoidal building system have mechanical and structural applications and can be manufactured using an automated process.

Sinusoidal shaped member units and support member units are parts that form pre-stressed assemblies having flexural properties. Sinusoidal shaped members are relaxed material members that have been elastically deformed. Support members maintain the elastically deformed state of the sinusoidal shaped members. The sinusoidal shaped members and support members are organized into pre-stressed curvilinear assemblies containing stored elastic potential energy that is equal to the work done by the forces that deformed their pre-stressed structure. The assemblies' sinusoidal shaped members and support members are adapted to use materials having exceptional mechanical properties and flexural strength. This includes nano-composites. The assemblies' pre-stressed state enhances its mechanical, electrical and structural performance. The size, number, density and possible geometric configurations of the sinusoidal shaped member units and support member units within an assembly/structure is vast. Products of this sinusoidal building system have mechanical and structural applications and can be manufactured using an automated process.

A building block system of a plurality of transportable, lightweight, and reusable hollow prefabricated non-masonry interlocking mortarless building blocks that have corresponding mating formations being protuberances and concavities that run vertically up the building blocks being joined together and when aligned in a staggered manner upwardly are held together with threaded reinforcement rods extending vertically between and connected to the top and bottom channels through connectable couplings and capped off with complementary cap attachments.

A curtain wall brick external wall, comprising a concrete external wall and an exterior decorative curtain wall brick (1). The concrete external wall is connected to the curtain wall brick (1) by a metal connecting piece, wherein the metal connecting piece has two types: the bolt type and the steel bar type, the bolt type comprising a bolt (3) and steel hoops (A, B, C) movable along the bolt (3) or other metal pieces. The external wall is easily constructed, and has a reliable connection.

A curtain wall brick external wall, comprising a concrete external wall and an exterior decorative curtain wall brick (1). The concrete external wall is connected to the curtain wall brick (1) by a metal connecting piece, wherein the metal connecting piece has two types: the bolt type and the steel bar type, the bolt type comprising a bolt (3) and steel hoops (A, B, C) movable along the bolt (3) or other metal pieces. The external wall is easily constructed, and has a reliable connection.

A prefabricated modular reinforced concrete building system includes panel assemblies for foundations, walls, decks, and roofs designed to be built out in a manufacturing facility, shipped to a job site, and filled with concrete. Panel assemblies incorporate a space frame to ensure structural integrity during shipping and during concrete fill. Space frames can include structural columns, rebar mats, spacers, straps, and skin panels. Panel assemblies may be manufactured to contain architectural interior/external finishes, windows/doors, and pre-installed utility distribution systems.

A prefabricated modular reinforced concrete building system includes panel assemblies for foundations, walls, decks, and roofs designed to be built out in a manufacturing facility, shipped to a job site, and filled with concrete. Panel assemblies incorporate a space frame to ensure structural integrity during shipping and during concrete fill. Space frames can include structural columns, rebar mats, spacers, straps, and skin panels. Panel assemblies may be manufactured to contain architectural interior/external finishes, windows/doors, and pre-installed utility distribution systems.

A new prefabricated wall panel is the basic unit of a new, more efficient and stronger wall system. The wall panel is manufactured from a plurality of foam sections sized to leave vertical and horizontal voids into which concrete is later poured, each foam section having an inner and outer surface and two sides; and a plurality of fastening strips. The fastening strips are longitudinal metal strips being situated between the sides of two foam sections. Each fastening strip has two longitudinal fastening strips projecting perpendicularly to the longitudinal fastening strip and the fastening strips being adjacent to the outer surface of the two foam sections. The fastening strip also has a plurality of clearance holes in the longitudinal fastening strip, a plurality of embed tabs projecting from the edge opposite the fastening strips, each embed tab having at least one hole, and between each pair of embed tabs, a foam tab to hold the two inner sides of the foam sections in place and partially separate the foam sections from the concrete to be poured into a form.